Systems and methods for use in retaining wall construction

ABSTRACT

The invention relates to systems and methods for covering portions of one or more block members after laying of the block members to allow filling of hollow cores in the block members with filler materials. A cover member prevents the filler materials from entering into channels or apertures covered by the cover member. A cover member has a top section and a downwardly depending member extending from the top section. The downwardly depending member extends into a portion of the block, and may engage with the block member to retain the cover member in position.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority to and the benefit of U.S. Provisional Patent Application No. 62/376,160 filed on Aug. 17, 2016, and is incorporated herein by reference in its entirety.

TECHNICAL FIELD

The present invention relates to a system and methods for use in installation of a retaining wall using cast concrete blocks adapted to be pinned together.

BACKGROUND OF THE INVENTION

In the formation of retaining walls that require reinforcement to withstand significant pressures from adjacent soil formations, products have been developed which allow individual formed blocks of material to be connected to one another to reinforce the wall formed therefrom. One type of block product, particularly useful for forming retaining walls, uses building blocks formed of a concrete material. The blocks stack one on another in rows or courses. In general, the blocks are slightly offset rearwardly from the row immediately below it. In another style, referred to as the flush mode, the forward ends or faces of the blocks are substantially flush with each other. In either form, the blocks are held together using pins or like structures which are inserted through holes or other structures and lodged in recesses or the like in the blocks. The blocks further include one or more hollow core sections provided for housing a reinforcement material, such as aggregate or gravel, that is backfilled into the hollow cores. The pins or the like will hold the blocks together in the desired configuration along with aggregate or gravel provided in the hollow cores of the blocks.

Installation of such retaining wall blocks leads to the problem of the filler, such as aggregate or gravel, used to fill the cores in the blocks tends to fill the channels and/or apertures in the block members used in pinning the blocks together. This requires cleaning out any such aggregate, gravel, or other debris prior to being able to stack another block on top of a laid block for pinning the blocks together. It would be desirable to prevent the aggregate, gravel or other backfill materials or debris from entering the channels and/or apertures in the blocks until another course of blocks are ready to be stacked on a lower course of blocks that have been laid and the cores have been filled with such aggregate, gravel or other backfill materials.

SUMMARY OF THE INVENTION

In an aspect, the invention relates to a cover system for block members having at least one hollow core and used in construction of a retaining wall. The cover system comprises a cover member having a top section and at least one downwardly depending portion from the top section. The at least one downwardly depending portion is positioned with respect to the top section such that it extends into at least a first structure formed in the top of at least one block, but leaving the at least one hollow core of the block uncovered. The top section may be dimensioned to extend over additional structures formed in the top of the at least one block. The structures covered by the cover system may be used for covering portions of the block used for positively engaging the block member to another block member.

In another aspect, the invention relates to a method for installing a retaining wall using block members stacked on one another. The method includes laying of a plurality of block members having at least one hollow core portion in at least one layer on a surface defining the base of the retaining wall. A cover member is positioned to cover channels, apertures or other structure formed in the block members. The at least one hollow core of each block member is not covered and is filled with a predetermined fill material. At least one further layer of a plurality of block members having at least one hollow core portion are laid upon the lower layer of blocks. The steps are repeated to form a retaining wall of predetermined specifications for each layer of block members. The cover members may be removed before the further layer of block members are stacked on a lower block member.

Examples are directed to systems and methods for covering the channels and/or apertures or other structure formed in the top surface of the block members used to form a retaining wall. The systems and methods allow for covering of portions of one or more block members before or after laying of the block members. This allows filling of the hollow cores in the block members with filler materials, while preventing the filler materials from entering into channels, apertures or other structures in the block members that may be used for securing blocks together in the wall construction. A cover member has a top section and at least one downwardly depending section or member extending downwardly from the top section. The downwardly depending section may have at least one radially outwardly extending portion which, in use, engages with structure formed in the block members. The at least one radially outwardly extending portion may provide an interference fit of the downwardly depending section or stem in the channel, aperture or other structure in the top portion of the block member. When positioned with one or more block members, the cover member covers the channel, aperture or other structure formed in the blocks to prevent filler materials or other debris from entering into the channel, aperture or other structure in the block members.

Other aspects of the invention will become apparent upon reading the following description in conjunction with the figures.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present invention will become better understood with regard to the following description, appended claims and accompanying drawings wherein:

FIG. 1 is an example of a retaining wall formed from a plurality of block members.

FIGS. 2A and 2B are sectional views of block members in pinned relationship to one another when stacked in the retaining wall of FIG. 1.

FIGS. 3A and 3B are end views of embodiments of a cover system for covering predetermined portions of a plurality of block members laid in forming a retaining wall, and FIG. 3C is a top view of another embodiment thereof.

FIGS. 4A-4C are top and side views of alternate examples of the invention configured to be left in place after installation with one or more blocks.

FIG. 5 is a top view of a plurality of block members with the system of FIG. 3 positioned therewith.

FIGS. 6A-6D are top views of alternate types of block members usable for forming retaining walls, that the invention may be configured for use with.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is described in detail with reference to examples and to the figures. As shown in FIG. 1, there have been developed retaining wall block systems 10 for construction of retaining walls by stacking of the blocks to a desired height and configuration. Such systems are used for commercial and residential retaining walls. For example, various block systems are designed for creating very large retaining walls around road and highway areas for example, or a multitude of other environments. Such systems generally include a plurality of blocks 12 formed into layers stacked on each other. The blocks 12 are generally formed of concrete or other suitable materials, and are engineered to form a retaining wall designed to retain earthen materials (or other materials such as water) behind its height. The height of walls constructed from blocks 12 may be significant, and in order to maintain desired structural integrity, such block members 12 may include designed features to allow the blocks 12 to be positively locked together. In the example of FIG. 1, the block members 12 include channels 14 and apertures 16 which allow pinning of the stacked block members together. The block members 12 also include at least one hollow core area 18. The hollow core area 18 allows for the introduction of predetermined filler materials, such as gravel, which is used to anchor each of the block members 12 in association with pinning or other structures to allow the blocks 12 to be positively locked together.

As shown in FIG. 2, example block members 12 are stacked on one another and positively locked together using a pin system. The pins 20 are designed to be inserted through apertures 16 in a top block 12 and to extend into a channel 14 of the lower block 12. The arrangement of channels 14 and apertures 16 in each block 12 allow for stacking in a setback arrangement as shown in FIG. 2A or a substantially flush arrangement as shown in FIG. 2B. To install the pins 20, the blocks 12 are stacked upon one another at predetermined relative positions to allow the pin 20 to extend through aperture 16 and into a channel 14 of the lower block 12. If any obstruction or debris is located in the channels 14 or apertures 16, proper pinning of the blocks 12 to one another is prevented. At the same time, it is necessary to backfill the at least one hollow core area 18 with a fill material once the layer of blocks 12 is laid. The backfill provides further required structural integrity for the retaining wall and also provides drainage regions. This step of backfilling generally results in the filler material getting into the channels 14 and/or apertures 16, which then prevents proper laying of a next layer of blocks 12 and/or pinning of an upper block 12 to a lower block 12. To avoid such a problem, at least the channels 14 and/or apertures 16 of the blocks 12 must have any debris from the backfilling step removed prior to laying of a next layer of blocks 12. This results in the significant extra labor and expense in the installation of the retaining wall, which it would be desirable to avoid.

Turning to FIG. 3A, a first example of a cover system 30 according to the invention is designed to avoid the above problem, and provides at least one cover member 32 for temporary covering of portions of one or more block members 12 after laying of the block members 12. This allows filling of cores 18 in the block members 12 with filler materials, while preventing the filler materials from entering into the channels 14 or apertures 16 in the block members. A cover or cap member 32 has a top section 34 and a stem section 36 extending downwardly from the top section 34. The stem 36 may have at least one radially outwardly extending portion 38 which, in use, engages with a channel 14 formed in the block members 12. The at least one radially outwardly extending retention member(s) 38 may serve to create an interference fit with the channel 14 or other structure in the top of blocks 12 to positively engage the channel 14 (or other structure) in the blocks 12. The at least one radially outwardly extending retention member(s) 38 may be angled to form a lead-in taper to assist with insertion into the channel 14, and then to engage and provide an interference fit of the stem 36 in the channel 14. When positioned with the block members, the cap 32 covers the channels 14 and apertures 16 formed in the blocks to prevent filler materials or other debris from entering into the channels 14, apertures 16 or other structure in the top of blocks 12 used for positively engaging the blocks 12 together.

In the example of FIG. 3A, the top section 34 has a predetermined width A with first and second edges 40 and 42. In the block member 12 shown in this example, the width A is approximately 2.35 inches (56.69 mm). In this example, the stem portion 36 extends downwardly at a location approximately 0.80 inches (20.32 mm) from a first edge 40 of the top section 34, forming a width B between edge 40 and stem 36. This results in a width C between the stem 36 of top portion 34 and edge 42 being approximately 1.55 inches (39.37 mm), which is designed to extend over the apertures 16 in block members 12 when the stem 36 of cover 32 is engaged in channel 14. The width B may be of any desired width to allow positive engagement of stem 36 into channel 14, and for ease of manufacturing. The stem 36 may be dimensioned to correspond to the dimensions of channel 14 or other structures formed in blocks 12. In this example, the stem 36 extends downwardly from the top section 34 a distance of approximately 0.4-0.6 inches, and in this example extend 0.49 inches (10.80 mm), but any suitable arrangement may be used. The retention member(s) 38 for engaging the sides of the channel 14 for retention of cover member 32 therewith may be formed as outwardly extending members angled toward the top section 34, with dimensions to slightly engage the sides of channel 14. In this example, a pair of retention members 38 are provided, and extend a width D from the stem section 36. In this example, the width D may be slightly greater than the width of channel or aperture in which it is positioned, such as approximately 1.60 inches (12.44 mm) which is slightly greater than the width of channel 14 in this example. The retention members or fins 38 of this example may also have a thickness of approximately between 0.02-0.06 inches, or in this example, 0.037 inches (0.93 mm), to allow deformation to create an interference fit with channel 14. The distance between the retention members or fins 38 of this example may be approximately 0.1-0.2 in. and in this example are 0.123 inches (3.13 mm), but any suitable arrangement may be used. The stem section 36 may extend from cover member 32 a dimension to substantially fill the channel 14 or other structure, to prevent the possible entrance of debris into the channel 14 or other structure. In many cases, the block members 12 have beveled or tapered edges as seen in FIG. 1, and upon backfilling, it may be possible that debris could enter the channel 14 or other structure at the locations between blocks 12, where these tapered edges are adjacent one another in adjacent blocks 12. The cover member 32 may be designed to prevent such ingress, such as by downwardly depending portions that cover the bevel or taper in a particular block configuration. Alternatively to the particular example, other dimensions or structures to position the cover member may be suitable and are contemplated as a part of the invention.

Any other suitable arrangements to allow temporary engagement with the sides of the channel 14 (or other structure) are contemplated in the invention, such as a deformable boss extending downwardly from the top section 34 or the like. It is also contemplated that the cover system 30 does not have to necessarily be engaged, such as frictionally, with the structure formed in blocks 12, but simply may include aligning structures extending downwardly that allow proper positioning of the cover system 30 in the desired temporary location in association with and to cover channels 14, apertures 16 or other structures formed in the top surface of the blocks 12. The cover system 30 may have any desired length for use in covering the channel(s) 14 and/or apertures 16 in one or more blocks 12. For example, the cover member 32 may be formed in ten (10) foot lengths, but any desired length is envisioned.

In another example of the invention as in FIG. 3B, the cover 32 may have one or more angled surfaces, such as a peaked or domed top 44 system that tends to cause any filler material used to fill the at least one hollow core 18 to slide off the top section 44. This angled, peaked or domed top 44 may facilitate prevention of any filler materials getting into the channels 14, apertures 16 or other structures of blocks 12 upon removal of the cover member 32 after backfilling the hollow core regions 18.

In another example of the invention as in FIG. 3C, the cover 32 may have a top section 46 having score lines 48 formed therein, to allow the length of the cover 32 to be easily adjusted simply by bending at the score line 48. Other suitable arrangements to allow simple length adjustment are also contemplated, such as notches formed at different lengths or the like, system that tends to cause any filler material used to fill the at least one hollow core 18 to slide off the top section 44. As also shown in this example, the top section 46 may have a handle portion 50 to facilitate removal of the cover 32 from its installed position with a one or more blocks 12 by simply pulling up on the handle 50. As another alternative, one or more of the ends of the cover member 32 may have an interconnecting structure 52 provided to allow lengths of cover members 32 to be interconnected together in the installed position with a one or more blocks 12. Any suitable interconnecting arrangements 52 to allow connection of lengths of the cover members 32 to one another are contemplated, such as a dovetail type connection as shown using male/female structure that mates together, a hook and loop fastening section at each end or other suitable connection.

Turning to FIGS. 4A-4C, alternate examples of the cover system of the invention are shown. In this example, the cover system 300 is configured to be installed in position with one or more blocks 12 prior to backfilling. After backfilling, the cover system 300 is left in place and a further layer or course of blocks 12 is laid on top of the cover system 300 in its installed position with one or more blocks 12. In this configuration, the cover system 300 may include one or more punch out portions 305 formed in the top 304 of the cover member 302. The punch out portions 305 may be formed using score lines, the material may allow for punching out a portion or portions 305 may be formed in any other suitable manner, to allow a pin 20 (or other like member) used to secure stacked blocks 12 together as previously described. The pin 20 (or other like member) breaks through the top 304 and into a locking position within channel 14 of the lower block 12, or in association with other structure to allow blocks to be secured together. The position of the portions 305 corresponds to the location of the channel 14 other structure to allow blocks to be secured together. Alternatively, instead of punch out portions 305, the cover member 302 may be made of a material that allows a pin 20 or the like to be punched through it relatively simply, while still providing the structural integrity to allow backfilling without debris entering the channel 14 or other structure. For example, the cover member 302 may be formed of a hard paper material, thin plastic material, or any other suitable material that allows a pin or the like to be punched through it relatively simply. The cover member 302 may also be formed of a biodegradable material that will degrade after installation of the retaining wall 10. As seen in FIG. 4B, the cover system 300 may have downwardly depending stem portions 307, which may be similar to the stem portions 36 previously described, but only positioned adjacent or at the ends of the cover system 300 or intermittently along the length of cover system 300, leaving the punch out portions 305 without any structure beneath them. Alternatively, as seen in FIG. 4C, the cover system 300 may have downwardly depending end portions 309, designed to extend over the side edge of a block 12 to be retained in place. The cover system may be made to correspond to a single block 12 or a plurality of blocks 12.

In an example, the system 30 or 300 may be fabricated of a material that has good durability, but also some amount of flexibility. As shown in FIG. 5, many times a retaining wall 10 has concave or convex curvatures. The cover system 30 or 300 of the invention may be designed to allow lengths to be flexed to accommodate such curvatures. For example, the material used to make cover system 30 or 300 may be a semi-rigid polyethylene that is extruded to form the system 30 or 300 in desired lengths. The cover system 30 or 300 may be formed of any suitable material, such as a plastic or paper material as noted, or alternatively, the material may be an elastomeric material. It may also be desirable to form the system 30 or 300 from a material that allows lengths to be rolled to facilitate cost-effective packaging and shipping. As described above, the cover system 30 or 300 may also be formed to fit an individual block 12, allowing pre-assembly of the cover system 30 or 300 with each block 12 separately before the block is laid.

Other examples of blocks 12 having at least one core region, used in forming retaining walls are shown in FIGS. 6A-6D. In the prior example of FIGS. 1 and 2, the blocks 12 are commercially produced and sold under the Versa-Lok brand by Kiltie Corporation, and referred to as the Square Foot block. This manufacturer also makes other block products using as least one hollow core region designed to be filled with particular filler materials, such as shown in FIG. 6A, referred to as an Ultra unit. In this type of block, similar channels 14 and apertures 16 are provided to positively couple the stacked blocks 12 together, by pinning. Or, in the block of FIG. 6B from the same manufacturer, referred to as the Nexus block unit, the block 12 includes channels 60 and extending bosses 62 around the core 18. The block 12 shown in the example of FIG. 6C is produced by Tensar International Corporation under the brand name Mesa Retaining Wall Systems, and this particular product is referred to as the Mesa Standard Unit. In this block, the structures formed on the top of block 12 include a channel 64 to accommodate a Mesa Standard Connector (not shown) as well as channel 66 along with channel 64 for accommodating an end of a geosynthetic reinforcing fabric/sheet used in constructing a retaining wall 10. A further block product 12 using as least one hollow core region designed to be filled with particular filler materials, is shown in FIG. 6D, being manufactured by Keystone Retaining Wall Systems, a Contech company, and is referred to as the Keystone Compac. In this example of a block 12, there is provided apertures 68 for pinning of the stacked blocks 12 together, and cavities 70 to accept pins when stacked on a block below. As seen in each of these different examples of FIGS. 6A-6D, the blocks 12 have at least one hollow core region designed to be filled with particular filler materials. Each block 12 also includes structures formed on the top surface thereof to allow positive coupling between stacked blocks, just as in the example described above with reference to FIGS. 1 and 2. Alternatively or in addition, as noted with other block configurations above, the blocks 12 may include structure on the top faces of the blocks for engaging and retaining geosynthetic reinforcing fabric/sheet or like products or with other materials used in constructing a retaining wall as will be appreciated by persons skilled in the art. As in the example of FIGS. 1-2, for each of these or other block configurations, the cover system 30 of the invention will be configured to cover the structures for positive coupling between stacked blocks to allow backfilling of the hollow core regions without debris getting into the structures for positive coupling or retention of materials between stacked blocks 12. Though not shown in detail with respect to each of these examples of blocks 12, a person skilled in the art would easily configure the cover system to operate in the manner as described, and such different configurations of the cover system 30 or 300 of the invention are contemplated within the invention. For example, the cover system 30 or 300 described with reference to FIGS. 1-5 above include a downwardly depending portion that would be configured to fit into the channels 14, 60, 64 and/or 66 in the examples above, with the top portion then configured to cover other structures on the top surface of blocks 12 while leaving the core 18 open for backfilling. Similarly, the downwardly depending portion could be configured to fit into the apertures 68 or cavities 70 of the example block 12 shown in FIG. 6D. It should also be recognized that these examples of blocks 12 are only examples, and there are a variety of other manufacturers and blocks 12 for which the cover system of the invention could be used. Further, in addition or in the alternative, the cover system 30 or 300 may include a downwardly depending portion that is dimensioned to extend into the hollow core 18 adjacent structures to be covered thereby, as a means to retain cover system 30 in a desired position in relation to the structures for positive coupling of stacked blocks, while still allowing backfilling of the hollow core regions 18 without debris getting into or around the structures.

In use, the cover system 30 or 300 is used in construction of a retaining wall 10. The method relates to installing a retaining wall 10 using block members 12 stacked on one another in layers to a predetermined height and configuration. The method includes laying of a plurality of block members 12, having at least one hollow core portion, in at least one layer on a surface defining the base of the retaining wall 10. A cover member 32 is positioned to cover channels 14, apertures 16 or other structure formed in the block members. The cover member 32 does not cover the hollow core 18. The at least one hollow core(s) 18 of each block member 12 are filled with a predetermined fill material. The cover member of the cover system 30 or 300 is then removed or left in place as described in examples, and at least one further layer of a plurality of block members 12 having at least one hollow core portion 18 are laid upon the lower layer of blocks and the blocks 12 are positively engaged to one another. These steps are repeated to form a retaining wall of predetermined specifications. The positioning of cover member 32 with a one or more blocks 12 simply requires snapping or inserting the stem section 36 into a channel 14 or other structure of blocks 12, with extension(s) 38 engaging the sides of the channel 14 or other structure of blocks 12 for retention of cover member 32 therewith. Thereafter, for the cover system 30, the cover member 32 is simply removed by pulling the cover member 32 out of the frictional engagement with channel 14 or other structure formed in the top surface of the blocks 12. Alternatively, the stem 36 may not be frictionally engaged but simply positioned in the channel 14. For a cover system 300, the cover member is left in place and the at least one further layer of a plurality of block members 12 having at least one hollow core portion 18 are laid upon the lower layer of blocks and the blocks 12 are positively engaged to one another. In another example, the cover system 30 or 300 is pre-installed on one or more blocks 12 to allow positioning of the blocks 12 in a retaining wall with the system in place, to allow immediate backfilling after installation.

The invention has been described with reference to examples presented above. Only examples have been presented and described in detail, it is to be understood that the invention is not limited thereto or thereby. It is therefore intended that the invention not be limited to the particular embodiments disclosed as examples of invention, but that the instant invention will include all embodiments falling within the scope of the appended claims. 

What is claimed is:
 1. A cover system for retaining wall block members having at least one hollow core comprising: a cover member having a top section and at least one downwardly depending portion from the top section, the at least one downwardly depending portion positioned with respect to the top section such that it extends into at least a first structure formed in the top of at least one block member, and the top section being dimensioned to extend over at least one additional structure formed in the top of at least one block member, but leaving the at least one hollow core of the block uncovered.
 2. The cover system of claim 1, wherein the downwardly depending portion is at least one stem member having at least one radially outwardly extending portion.
 3. The cover system of claim 2, wherein the at least one radially outwardly extending portion is dimensioned to engage with the at least first structure.
 4. The cover system of claim 2, wherein the at least one radially outwardly extending portion is angled to form a lead-in taper to assist insertion into the at least first structure.
 5. The cover system of claim 1, wherein the at least first structure is a channel or an aperture.
 6. The cover system of claim 1, wherein the at least one additional structure is at least one channel, aperture or boss.
 7. The cover system of claim 1, wherein the at least one additional structure is a feature to allow stacked blocks to be positively locked together. The cover system of claim 1, wherein the cover member is formed to mate with a plurality of blocks.
 9. The cover system of claim 7, wherein the cover member is made of a material that can flex to curve between a plurality of blocks.
 10. The cover system of claim 1, wherein the cover member is dimensioned to fit on a single block.
 11. The cover system of claim 1, wherein the cover member is made of a material that allows a block retaining member to be punched through it, while providing the structural integrity to allow backfilling of the at least one hollow core without material entering into the covered area of the block.
 12. The cover system of claim 1, wherein the cover member includes at least one punch out portion.
 13. The cover system of claim 1, wherein the cover member is made of a biodegradable material.
 14. The cover system of claim 1, wherein the cover member is made to be removed from the at least one block for reuse.
 15. The cover system of claim 1, wherein the cover member includes at least one angled top surface.
 16. The cover system of claim 1, wherein the top section of the cover member has at least one end provided with an interconnecting structure to allow cover members to be interconnected together.
 17. A cover system for retaining wall block members having at least one hollow core comprising: a cover member having a top section and at least one downwardly depending portion extending from the top section, the top section being dimensioned to extend over at least one structure formed in the top of at least one block member while not covering the at least one hollow core, and the at least one downwardly depending portion positioned with respect to the top section such that it extends into at least an aperture formed in the top of at least one block member.
 18. The cover system of claim 17, wherein the downwardly depending portion includes a retaining structure to engage the block member and at least temporarily retain the cover member in position with at least one block member.
 19. The cover system of claim 1, wherein the cover member is pre-installed in association with a block member.
 20. A method of constructing a retaining wall structure formed of a plurality of block members stacked in layers to a predetermined height and configuration, wherein the block members have at least one hollow core, comprising: laying of a plurality of block members having at least one hollow core portion in at least one layer on a surface defining the base of the retaining wall, positioning a cover member to cover structures formed in the block members, while not covering the at least one hollow core portion of the block member, filling the at least one hollow core portion of one or more of the laid block members with a predetermined fill material, laying at least one further layer of a plurality of block members upon the lower layer of blocks, and repeating the steps to form a retaining wall of predetermined dimensions. 